integrated services workshop services workshop services –
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Industry Sector, Mobility DivisionPage 1 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Industry Sector, Mobility Division
Integrated Services Workshop Services Erlangen, 2009
Integrated Services Workshop Services –
Refurbishment and Accident Repair
Erlangen, 2010
Industry Sector, Mobility DivisionPage 2 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Our skillsProject ManagementDamage assessment and surveysConsultingEngineering
Integrated Services – Your partner for refurbishment
and accident
repair
Mechanical and electrical installationWelding expert knowledge (IWE, EWS, NDT experts)Commissioning
Extension of operational lifetimeModernization / retrofitas complete solutionIndividual support: supervision, engineering, commissioning, etc.Revisions
Refurbishment Workshop Services -
worldwide
Complete solution approachRepair at Siemens- or customer facilitiesConsulting and implementationAll types of damagesAll types of vehicles
Accident Repair
Industry Sector, Mobility DivisionPage 3 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
We offer customized and specific solutions – Refurbishment for one vehicle or for the complete fleet
Refurbishment of Complete FleetsExtension of the vehicles’
operational lifetimeRetrofit of Systems
Update for individual vehicle components and systems
Commissioning and DocumentationReady-to-operate and homologated vehicles
Refurbishment of ComponentsExchange or revision of individual components
Industry Sector, Mobility DivisionPage 4 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Infrastructure
Rail connection to main line tracks
Welding hall with alignment table for complex works
Overhead cranes and bogie-drop table
Elevated tracks with pits and roof access platforms
Facilities for static and dynamic testing
Additional facilities like vehicle scale,
leak tightness test equipment and rotary-tilt table
High quality infrastructure – Siemens Mobility site Wegberg-Wildenrath
Industry Sector, Mobility DivisionPage 5 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Refurbishment has many characteristics – We provide the answers
Metro São Paulo Desiro UK Class 450Guadalajara Locomotive
BR 189
Refurbishment of the whole vehicle fleet
Enhancement of the passenger capacity
Refurbishment of thetraction system
ETCS retrofit for cross border operation (e.g. ETCS, ATB, SCMT)
Industry Sector, Mobility DivisionPage 6 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Vehicle type: Metro
Quantity: 150 wagons
Scope:Replacement of original DC by new AC Traction System(DC chopper exchanged with IGBT inverter and DC drives replaced by AC drives)Installation of a new „fail-safe“ braking systemBogie revision including adaptationsNew on-board electrical system with battery chargerNew interiorModification of the driver’s cabAir conditioning systemDoor revisionNew air compressor and revision of the pneumatic systemFire alarm systemAudio and video systemTrain control system
Carried out in a consortium with Alstom
Duration:2009 until 2014
Complete fleet refurbishment in São Paulo – Upgrading the vehicles to „state-of-the-art“
Fleet refurbishment
Industry Sector, Mobility DivisionPage 7 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Modernization from DC to AC Traction System The way to a higher car reliability in Guadalajara
New AC traction system
Vehicle type: Tram
Quantity: 16
Customer requirements:Higher reliability after implementation of anAC traction systemImproved spare part service; obsolescence prevention for DC traction equipment and stock optimization due to usage of common spare partsVehicle combination with other AC tram vehicles inmixed train consists (TLG-88 and TEG-90)
Scope:Inverter with IGBT technology, braking resistor and AC drives (including additional chokes)Replacement of original Knorr brake control system by Siemens airbrake control systemHigh Speed Circuit BreakerSet-point transducer for coupled operation with other tram vehiclesNew master controller and driver’s desk modification
Duration:2009 to 2011
Industry Sector, Mobility DivisionPage 8 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Vehicle type: Desiro Class 450
quantity: 28
Customer requirements:Interior retrofit to improve the transport capacity Planning of new outline for several types of carsExecution of works at Bournemouth Depot
Scope:Disassembly of the existing seat modules (3 seats)Remove of big litter bins, tables and curtains Mechanical works on the floor (e.g. holes, carpet)Installation of new seat modules (2 seats)Assembly of new side handrailsReworking of interior doorsInstallation of small litter bins behind glass dividerSealing of holes that are no longer usedRepair of carpet
Duration:August 2007 until July 2008
More and more passengers are using the rail – Increased transportation capacity for Desiro UK
Modification for raised transportation capacity
Industry Sector, Mobility DivisionPage 9 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Vehicle type: BR 189 (Mitsui) Quantity: 85
Customer requirements:Disassembly of existing ATC systems Adaption of mechanical and electrical interfacesInstallation of new ATC / ETCS components
Scope:Transport of locomotives into Siemens workshopMechanical and electrical disassemblyMechanical adaptation for new ATC components Installation of new components and rewiring(e.g. displays, sensors, electrical cabinets, antennas)Installation of a new pantographCheck of insulationCommissioning including static and dynamic tests Documentation of performed work
Duration:December 2007 until the end of 2010
Transnational traffic increases – rules and regulations to be fulfilled with ETCS upgrade
ETCS upgrade
Industry Sector, Mobility DivisionPage 10 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Our skillsProject ManagementDamage assessment and surveysConsultingEngineering
Integrated Services – Your partner for refurbishment
and accident
repair
Mechanical and electrical installationWelding expert knowledge (IWE, EWS, NDT experts)Commissioning
Extension of operational lifetimeModernization / Retrofitas complete solutionIndividual support: supervision,engineering, commissioning, etc.Revisions
Refurbishment Workshop Services -
worldwide
Complete solution approachRepair at Siemens or customer facilitiesConsulting and implementationAll types of damagesAll types of vehicles
Accident Repair
Industry Sector, Mobility DivisionPage 11 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
One-Stop Service – complete solutions for accident repair
Welding / LevelingExtensive welding and leveling expertise
Inspection and Damage AssessmentSurvey and repair concept evaluation
from one source
Complete Repair Processing Worldwide at the customer facility or in
Wegberg, Germany
Commissioning / DocumentationPreparation of commissioning and
customer documentation
Measuring3D-laser measuring or conventional,
as required
EngineeringCalculations, structural analysis,
FEM models
Industry Sector, Mobility DivisionPage 12 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Infrastructure
Rail connection to main line tracks
Welding hall with alignment table for complex works
Overhead cranes and bogie-drop table
Elevated tracks with pits and roof access platforms
Facilities for static and dynamic testing
Additional facilities like vehicle scale,
leak tightness test equipment and rotary-tilt table
High quality infrastructure – Siemens Mobility site Wegberg-Wildenrath
Industry Sector, Mobility DivisionPage 13 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Independent of the used welding material – The workshops comply with the highest quality standards
Materials Aluminum Stainless steel
Steel
ISO 9606 -
2 ISO 3834 -
2 ISO 14731 ISO 15614 P.1+2
Qualification test for welding operator
Quality requirements for
welding
Welding coordination Welding techniques
ISO 9001 –
Quality Management
Compliant to DIN EN 15085 –
welding on railway vehicles and components
Standards
Content
Certificates
Techniques MIG -
Metal Inert Gas
MAG –
Metal Active Gas
TIG (WIG) -
Tungsten Inert Gas
Electron beam welding
Industry Sector, Mobility DivisionPage 14 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
No matter what damage – We can assist you
Desiro Classic
ÖBB Combino MelbourneHeidelberg MGT6 Mannheim MGT6D
Front and side damageregional train aluminumvehicle
Front damagelight rail aluminumvehicle
Side damagelight rail steel vehicle
Front damagelight rail steel vehicle
Industry Sector, Mobility DivisionPage 15 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Accident repair of a Desiro Classic with front and side damage after crash with concrete truck
Date of accident:July 2008 in Austria
Damage:Complete vehicle front (GRP head)Vehicle front end base frameComplete left side
Challenge:Disassembly of vehicle at customer workshopTransfer of damaged vehicle to Siemens workshopReconstruction of side panel, base frame and GRP headComplex welding worksReassembly under supervision of Siemens at customer workshopCommissioning support
Actions:Fabrication of a new vehicle front and body partsPartial replacement of the left side wall panel
Duration:December 2008 until September 2009
Front-
and side damage –
Desiro Classic ÖBB
Industry Sector, Mobility DivisionPage 16 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Accident repair of a damaged MGT6 tram after crash caused by false track switch position
Side damage –
Heidelberg MGT6
Date of accident:June 2009 in Heidelberg, Germany
Damage:Side damage after collision caused by false track switch positionHeavy car body and base frame damagePartly detached vehicle front at front door
Challenge:Disassembly and reassembly of vehicle Repair of base frame and vehicle frontLeveling of the car bodyComplete repair at Siemens workshopCommissioning at Siemens Test- and Validationcenter
Actions:Reconstruction of base frame structure till main crossbarMeasuring of complete car shell incl. leveling workUsage of specific flexible welding fixtures
Duration:September 2009 until January 2010
Industry Sector, Mobility DivisionPage 17 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Accident repair of a COMBINO with frontal damage after rear end collision of two light rail vehicles
Frontal crash –
Combino Melbourne
Date of accident:September 2007 in Melbourne, Australia
Damage:Complete vehicle front and rear end (rear-end collision)Vehicle front base frameFront coupler
Challenge:Transfer of vehicle to GermanyComplete repair at Siemens workshop
Actions:Procurement of main partsTransfer to GermanyRedesign and fabrication of a new aluminum front structureUsage of specific welding tools and welding fixtures
Duration:April 2008 until September 2008
Industry Sector, Mobility DivisionPage 18 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Accident repair of a MGT6 car with frontal damage after rear end collision
Crash -
Mannheim MGT6
Date of Accident:February 2009 in Mannheim, Germany
Damage:Heavy front and base frame damage
Challenge:Disassembly and reassembly of vehicle Repair of base frame and vehicle frontComplete repair at Siemens workshopCommissioning at Siemens Test- and Validationcenter
Actions:Reconstruction of vehicle frontUsage of specific flexible welding fixtures
Duration:April 2009 until December 2009
Additional order:Measurement of wheel vertical forces at Siemens Test- and Validationcenter
Industry Sector, Mobility DivisionPage 19 I MO RS IS RET RCopyright © Siemens AG 2009. All rights reserved.
Industry Sector, Mobility Division
Integrated Services Workshop Services Erlangen, 2009
Integrated Services We keep rail systems running